Design, Manufacturing & Analysis of Differential Crown Gear And Pinion for MFWD

Axle
V. MANUAL DESIGN CALCULATIONS FOR CROWN GEAR AND PINION

Slip torque = laden wt. on front axle index radius

= 2500 9.81 .65
= 15941.25 Nm
Peak torque (Mp) = 1.5 Slip torque
=1.5 15941.25 = 23911.875 Nm
Torque transmitted by pinion ( M t )

Mp
Mt
is i b
is =epicycle gear ratio,
Where,

i b =Conic set ratio

23911.875

6 2.9
3
1374.245 10 Nmm
Now, tangential load on pinion tooth (Pt)
2 Mt
Pt
Dm
m Zp b sin
Dp b sin
But g
where rm=mean radius(mm)
rm g 2 2
2 2

b
taking , 0.3 where , Ao =cone distance
A0
2 2
Dp Dg
A

2 2 as, Z p =11 and Zg =32
11
m
32

2 2
= 16.9189 m
b = 0.3 A o = 5.0757m
11 5.0757m 11
rsin m
18.97 .. tan 1
m
2 2 p 32

=4.675 m ...pinion
Dm = 9.350 m
3
2M t 2 1374.245 10
Pt
Dm 9.35m

Second National Conference on Recent Developments in Mechanical Engineering 63 | Page

M.E.Society's College of Engineering, Pune, India
 3
Pt 293.956 10
m
Material selected = 18_NiCrMo5
A b
Pt = C bmy
ball v
' 0

A0
= 1/3 Sut =1/3 2069=698.667 N/mm
2 2
b ( Sut =2069 N/mm )
Where, all

3
Vm D m
N 9.35m 409.53 10 =.2005m
60 60
3.5 0.2005m
3.5 V
m
(Velocity factor) Cv 1 0.128 m
3.5 3.5
2 402 1400 2 N
Where, Vm=
1400
60 60
N=409.53 rpm

Zp ( 18.97 , 34.88 ) ,
. (T =equivalent teeth on pinion)
T
EP 3 p
cos p cos EP
11
TEP 3 = 21
cos(18.97) cos (34.88)

' 0.912
y 0.154 .111
TEP

Putting all value in (*) we get

3
293.956 10
698.667 (1 0.128 m ) 5.0757m m
0.111 .7 m
m = 6.38 mm
Selecting standard m =6.50 mm
Dm 9.35m 9.35 6.5 60.775mm
, b=5.0757m =33mm,
A 0 =16.9189m=109.973mm

3.5 V m
Vm =0.2005m=1.30 mm/s , Cv =1.3257
3.5
3
b (1 0.128 6.5) 5.0757 6.5 6.5 0.111 .7
293.956 10
actual

6.5

2
b actual
= 651.517 N/mm
b
b actual
< all

So design is safe at peak load

Now for 90% duty cycle
Pt(working)= 0.5 Pt
 =0.5 45.224 KN
=22.612KN
Checking for continuous working
A b ..*
C bmy
Pt = b v actual
' 0

A0

109.973 33
bactual
22.612= 1.3257 33 6.5 .111
109.973
2
b =325.79N/mm
actual

b
b < actual
all
 Design is safe.
VI. MODELLING AND FINITE ELEMENT ANALYSIS
After completing design of crown gear and pinion theoritically by usin g given data (Table.1) and to perform
FE analysis of any component, the solid model (Fig. 8) of the same is essential, so we modeled crown gear
(Fig.8) and pinion in PRO-E (wildfire4.0) which is excellent CAD software , which makes modelling so easy
and user friendly.The model is then transferred in IGES format and exported into the Analysis software
ANSYS 13.0
.We analysed gear tooth (Fig. 9) in ANSYS by importing IGES file of tooth. First is pre-processing which
involves modeling, geometric clean up, element property definition and meshing. Next comes, solution which
involves imposing boundary conditions and applying loads on the model and then solution runs. Next
in sequence comes post processing, which involves analyzing the results plotting different parameters like
stress, strain.

Fig. 8 3-D model of assembly and tooth 2-D view of Crown gear